Project overview
The station called for a highly visible envelope capable of meeting exacting structural, fire, acoustic and weathering requirements. Ten pitched roof zones, each with different geometry, removed almost all opportunity for repetition.
Thornton’s package combined the Kalzip roof with bespoke external soffits, concealed PVC-laminated gutters, aluminium ridge and eaves flashings, walkways and freestanding handrails.
Blast-resistance criteria required finite-element modelling, reinforced clips, increased fixing density and a redesigned support structure. More than 500,000 fixings were installed under enhanced inspection and test-plan controls.
Panels reached 38 metres. A mobile roll-former was craned to roof level for upper zones, while just-in-time deliveries, engineered crane pads and laser set-out kept work moving above a live viaduct.
The envelope achieves continuous weathering, airtightness and thermal performance with an A1 non-combustible build-up. The specialist team delivered the technically complex roof on programme.
“Thornton delivered an exemplary service. The scope and complexity demanded technical expertise, meticulous planning and disciplined execution—and their collaborative approach contributed significantly to its successful delivery.”
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